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Service manual
2 BOC Smoothcut Advance MIG 275R & MIG 350R Service manual Ver.1 Rev.1 . 0314
Warranty Information
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Ver.1 Rev.1 . 0314 BOC Smoothcut Advance MIG 275R & MIG 350R Service manual 3
Contents.
1.0 Fundamental schematic and circuit diagrams 4
1.1 Wiring diagram for Advance MIG 275R 4
1.2 Wiring diagram for Advance MIG 350R 5
1.3 Advance MIG 275R/350R boards 6
J3 1 15V
2 GND
3 voltmeter
4 Ampere meter
5 GND
6 Arc characteristic
7 GND
8 Volt Set signal
J2 1 GND
2 Set wire feed speed
3 Once pin 4 is at high potential, fast wire speed;
once at low potential, low wire speed
4 12V
5 Once pin 5 is at high potential check gas;
once at low potential, do not check gas
6 12V
7 NC
8 NC
9 Once pin 2 is at high potential, 2T; once at low
potential, 4T
10 12V
Ver.1 Rev.1 . 0314 BOC Smoothcut Advance MIG 275R & MIG 350R Service manual 7
CON3 AC240V
CON4 AC240V connect solenoid valve
CON6 1 GND
3 24V
CON7 1 GND
2 +DC340V
K1 Solenoid valve relay if the solenoid valve is not pulling in: if 24V relay pulls in solenoid valve
damaged; if 24V relay does not pull in Q1 Z24 circuit damage check it.
K2 Slow starting relay
RX1 Field-discharge resistance: if startup frequency is high, field-discharge resistance will break
off cool down for a while and re-start.
Caption needed
Ver.1 Rev.1 . 0314 BOC Smoothcut Advance MIG 275R & MIG 350R Service manual 9
10
Ser. No. Pin Description Ser. No. Pin Description
CON9 1 Current feedback signal
CON1 DC auxiliary current,MIG275R DC auxiliary current
2
is 310V,while MIG350R is 540V,if the above DC
3 GND
auxiliary current needs to be repaired,particular
4 Voltage feedback signal
attention must be paid to the positive and
CON10 1 24V
negative pole
2 Guard lamp
CON2 1 24V
3 24V
2 GND
4 Power light (NC)
CON3 1 5V
CON11 1 15V
2 Arc characteristic signal
2 GND
3 GND
CON12 Current detection signal
4 NC
CON13 Drive signal
CON4 1 Current detection signal, if pin 1 is at low potential,
CON14 1 GND
no output current; if high potential, no output
2 24V
2 GND
3 24V
CON5 Mutual inductor, current sampled signal
4 GND
CON6 1 5V
5 GND
2 Volt Set signal
6 GND (pin 5 and pin 6 short circuit)
3 Lowest Volt Set signal
7 24V seal signal
4 GND
CON15 NC
CON7 CON7 pin 2 voltmeter sampled signal
CON8 1 5V
2 Ampere sampled signal
3 GND
10 BOC Smoothcut Advance MIG 275R & MIG 350R Service manual Ver.1 Rev.1 . 0314
1 GND
2 GND
3 Seal signal pin. Seals if low potential, lower 3525 pin 8.
4 GND
5 NC
6 15V
7 Overheating protection signal: if low potential, overheating protection
is activated.
8 NC
9 Over current protection: Pin 9 is a mutual inductor current sampled signal. If
the potential is higher than the set value, it will close
10 GND
11 24V
12 Set signal
13 GND
14 Drive signal
15 15V
16 Drive signal
17 24V
18 Drive signal
19 NC
20 Drive signal
21 NC
22 GND
12 BOC Smoothcut Advance MIG 275R & MIG 350R Service manual Ver.1 Rev.1 . 0314
1 Switch on and no response 1 The external power supply is abnormal, power wires may 1 Check and confirm whether the input voltage into the
not be properly connected; (Test point 1, test the input machine, no over-voltage or under-voltage condition,
voltage on the EMC board and power board input pin) make sure the power cord is connected correctly.
2 Rectifier silicon bridge damage causes the input to 2 Test the performance of the rectifier silicon bridge
short circuit.
2 Switch on,fan is working, 1 Torch switch is damaged or the control wire is loose 1 Check the torch control wire
turn on the switch of welding 2 Poor contact of the torch and the power source or wire 2 Reconnect the wire feeder
torch, but still no response feeder connections 3 Detect if it’s 24V with a multimeter, if not, check the
3 The auxiliary power supply has a circuit failure control board auxiliary power for any component
damage
3 Power light is on, the fan 1 Bottom board PZ-60-A degaussing resistance damage, the 1 Check and replace the components or bottom board
stops after a while, or once main relay K2, 7D361 pressure-sensitive resistor damage 2 Check whether the voltage exceeds AC 380V or grid
the torch switch is pressed, 2 The supply voltage is too high, causing over-voltage voltage is too high
the machine shuts down protection to activate 3 Stop for a few minutes, allow the resistor to cool
3 Continuously switching on and off within a short period before restart.
of time resulting in the startup resistor overheating. 4 Check whether the auxiliary power part MOSFET,
Can’t start up. IC3843, resistors and other components are damaged
4 The control board auxiliary power supply is damaged and if so, replace.
4 Start up and the air switch 1 Power wire or power supply bottom board short circuit. 1 Replace the power wire or repair bottom board.
breaks 2 Over-voltage causes damage to the varistor. 2 Replace the varistor, re-adjust the input voltage.
3 Damage to the silicon bridge causes short circuit 3 Check for a short circuit with a multimeter and replace
the silicon bridge
5 Start up, no gas feed or valve 1 Gas circuit is blocked. 1 PZ-60-A relay K1 pulls in, replace the solenoid valve
not working, other functions 2 The valve control circuit is damaged 2 Inspect and replace if needed
are normal
3 If PZ-60-A has 24V, and the relay does not pull in,
then check the valve control circuit components, i.e.
MOSFET, Z24 and wire circuit
6 Press the torch switch, 1 Measure the control panel PK01-077-A whether the drive 1 If not 24V, then the R70 (1 ohm) resistor is damaged
gas flows, but no voltage is 24V with a multimeter; 2 Check whether there is a drive waveform from the
indication in the panel (no 2 Seal wave, without drive waveform 3525 chip, check the circuit in this area;
load), wire feeder is not
3 No wave 3 Wire feed board PHB-93 control circuit: Check CON1
working
pin 7. Check seal-wave control signal. If pin 7 high,
transistor Q5 damaged and needs replacing
7 Press the torch switch, 1 Wire feed board wire feed MOSFET and control circuit 1 Check whether there is a cold joint in wire feed board
gas out, there is a voltage damaged PHB-93 Q1;②check TL494 pin 4 potential; If high,
indication in the panel (no 2 Wire feeder control wire③④ broken or poor contact replace TL494
load) but the wire feeder is 2 Check and replace in needed
not working
8 Press the torch switch, 1 The 2nd rectifier module is damaged 1 Check the performance of rectifier module and replace
abnormal indication light on, 2 The IGBT or drive circuit is damaged 2 Check the performance of IGBT module or LED light in
no output the IGBT board, resistors, tantalum capacitors, single
tube IGBT and the diode. Replace board
9 Abnormally high welding 1 Machine is overheating and causes overheating 1 Check whether the fan is damage and causes
current or abnormal indicator protection to activate overheating
light while welding 2 IGBT absorption board failure 2 Check IGBT absorption cement resistors, and capacitors.
If damaged, replace.
Ver.1 Rev.1 . 0314 BOC Smoothcut Advance MIG 275R & MIG 350R Service manual 15
10 Porosity in the weld 1 Solenoid valve does not respond: 1 Check and replace if needed
a Solenoid valve coil broken; 2 Adjust or replace
b Solenoid valve cable broken;
c Solenoid voltage control circuit damaged;
2 Lack of shielding gas:
a The gas flow rate is too low
b The solenoid valve is blocked
c Check the connection between the cylinder and torch,
also check the inside of the gas tube
d If using CO2, the regulator heater power supply may not
have been turned on or is not being used.
11 Welding current unstable 1 Output controlling voltage is not stable 1 Adjust suitable voltage with current.
and large spatter 2 Voltage and current are not adjusted in right position 2 Adjust again
3 The potentiometer has been damaged 3 Replace
4 The unstable current is caused by using incorrect size 4 Replace
contact tip 5 Replace
5 Wire-feeder has been damaged or wire feed rolls are worn 6 Replace
6 Wire-feeder guide tube is aged 7 Replace
7 The torch has been damaged or is worn 8 Shorten stick out
8 Wire stick-out is too long
16 BOC Smoothcut Advance MIG 275R & MIG 350R Service manual Ver.1 Rev.1 . 0314
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believed to be correct at the time of printing. Whilst proper care has been taken in the preparation, no liability for injury or damage resulting from its improper use can be accepted.